BS/021110/SH-SG(2000GB)热轧精益生产试点成果汇报机密February9,2003此报告仅供客户内部使用。未经麦肯锡公司的书面许可，其它任何机构不得擅自传阅、引用或复制。ImproveHRM’sproductquality,OEEandstabilitywithleanmanufacturingBS/021110/SH-SG(2000GB)2EXECUTIVESUMMARY•HRMhasachievedsignificantoperationimprovementduringthesixmonthpilotperiod.Both1580and2050improvedtheirOEEandqualitylevel.Therealizedbottomlineimpactduringthepilotreached63.1MlnRMB,andtheannualizedfinancialimpactis150MlnRMB.HRMhasgraduallybuilditsoperationalimprovementcapabilitiesthroughoutthepilotingprocess.LeantoolsandimprovementmethodswerewidelyusedinHRMinsolvingproblems.Moreover,leanandsixsigmatoolswerecombinedinsolvingsomequalityproblems.AgroupofimprovementexpertsaredevelopinginHRM.Inordertosustainthepilotresultsandensurethecontinuousimprovementefforts,HRMalsomadechangesinitsperformancemanagementsystemandbeguntheimplementationsincebeginningofthisyear.HRMhassetdetailedrolloutplanfor2003tofurtherimproveproductqualityandOEE,Baosteelcompanywiderolloutplanisalsounderdevelopment.–Sixpilotqualityproblemshaveimprovedsignificantly,forridge,scale,width,rollingcrack,edgedamagefoldingedge,averageincreaserangingfrom24%to67%,andforthicknessprecision,improving1%.–Workrollchangetimeinboth1580and2050reduced30%to10minutes,backuprollchangealsoreducedundertarget–Maintenanceefficiencyinboth1580and2050improved10%,thestoppagetimeoftwoequipmentstrategypilotingequipmenthaspotentialtodecrease55%and53%.–PerformancemanagementteamdesignedHRM’sperformancemanagementsystemandprocess,settingupKPIsandKPItargetsfor163HRMpositions.•ThesuccessfulpilotexperienceinHRMhassetagoodexampleforBaosteeloverallimprovementprogramandbuildasolidfoundationforBaosteeltorollout“leansixsigma”programcompanywide.BaosteelshouldselectaseriesofimprovementprojectsbasedonBaosteelownbusinessstrategyandfinancialgoals.Atsametime,thoseimprovementprojectswouldprovideatraininggroundforagroupofBaosteelownimprovementexperts.BS/021110/SH-SG(2000GB)3Agenda•HRMLeanPilotProgressOverview–Summaryofpilotresults–Qualityimprovement–Rollchange–Maintenance–Performancemanagement•BaosteeloperationalimprovementrolloutplanBS/021110/SH-SG(2000GB)4BAOSTEEL’SUNIQUESITUATIONREQUIRESINTEGRATINGLEANAND6σACCORDINGLYANDINATAILOREDAPPROACHStrategicChange•Increasingdemands,especiallythoseinhigh-endproducts(e.g.automobilesteel),requirethequalitytoreach“zerodefect”towinthecompetition•CustomerswidelyuseJITproduction,consequentlyrequiringBaoSteeltodeliveryproductsJIT•Pricecompetitionisthelastingissueinthesteelindustry•InvestmentmanagementisalsoanotherimportantlevertoimproveROCforcapitalintensivebusinessBaoSteelneedstointegratethebestofleanand6σandtodesignandimplementoperationprogramtoaddressitsuniqueoperationalchallengesOperationalChallenge•Howtoimprovetheprocesscapabilityandstabilityalongtheentirevaluechain,deliver“zerodefect”productstohigh-endcustomers(e.g.automakers),andincreasecapacitytoraiseproductionvolume?•HowtoeliminatewastesinthevaluechainviaJITproductiontoimproveon-timedeliveryfromcurrent70~80%to>98%?•Howtoreducecosttofacethepricecompetition?•Howtobuildthecontinuousimprovementcapability,insteadofthespikesinimprovement?BS/021110/SH-SG(2000GB)5HRMPILOTFOCUSEDONPRODUCTQUALITY,MAINTENANCEEFFICIENCY,ROLLCHANGEANDEQUIPMENTSTOPPAGE1580OEE–2001Hrs8,7607631,2246,77354043657971...
